Zhejiang Feida Environmental Science & Technology Co.,Ltd.

Electrostatic Precipitators
Erection Manual

Address: 88 Wangyun Road, Zhuji City, Zhejiang Province

TEL: +86-575-87211558
FAX: +86-575-87383308
E-mail: ftd@feidaep.com
Post code: 311800
 Contents

1. Range of Application

2. Normative Reference

3. Storage and Open-case Inspection of the Equipment

4. Preparations before Construction

5. Erection of the ESP Proper

6. Cautions during Erection

7. Final Inspection of Erection

8. Items of Commissioning after Erection

9. Mounting of High-strength Bolts

Appendix A: Unmarked Erection Tolerance List of ESP

Appendix B: Commissioning Outline of ESP

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1 Range of Application

1.1 This manual applies to the proper erection of electrostatic precipitator (ESP) and

can also be used as reference for technical reconstruction and overhaul.

1.2 When the special rules of similar type ESPs imported from abroad as well as

some products disagree with this manual, those special rules should be carried

out.

2 Normative Reference

Clause in the following standards that have been quoted by this manual will

become part of this manual.

GBJ232-82 Regulations for the Construction and Acceptance of Electrical

Erection Projects

JB6407 Safety and Technical Regulations for the Commissioning,

Operation and Maintenance of ESPs

JB/T8536 Technical Requirements for the Erection of ESP’s Mechanical

Portion

JB/T5906 Collecting Plates for ESPs

JB/T5909.1-4 Porcelain Insulators for ESPs

JB/T5910 Electrostatic Precipitator (ESP)

Q/FHK08 Coating Specifications for Steel Structures

Q/FHK19 Packing Requirements for Steel Structures and Their Accessories

3 Storage and Open-case Inspection of the Equipment

3.1 Storage of the equipment after its arrival at the jobsite should be as follows:

3.1.1 The place for storage should be properly arranged. It must be a solid area

with flood control and drainage measures and suitable for loading and unloading.

3.1.2 The piling of equipment parts/components should be in such an order that

facilitates their pre-assembly and erection according to technological sequence so as

to avoid being damaged due to repeated handling.

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3.1.3 The packing, transportation, marking and storage of ESP’s parts/components

should follow Q/FHK19.

3.2 Open-case inspection.

3.2.1 The open-case inspection of equipment should be jointly carried out by the

manufacturer, the customer and the erection contractor.

3.2.2 Conditions of acceptance.

a. There are complete technical documents such as packing list, supplying list,

etc.

b. Model number, specification and quantity shown by the name plates on the

equipment are as correct as those in engineering design.

c. The quality of the equipment is to be checked. If there is any deformation or

variation in dimensions caused during handling, transportation or storage,

corrective measures should be taken for those affected parts/components, for

any parts that can not be repaired, they should be discarded and replaced

them.

d. Criteria of acceptance of equipment are drawings from the manufacturer

relevant technical documents and standard JB/T5910

4 Preparations before construction

4.1 The erection contractor must be familiar with the structure and performance of the

equipment, relevant design drawings and technical documents. He should make the

construction organization plans, compile construction quality sheets and make

records of erection quality inspection in a strict way.

4.2 Work involving ground leveling, platform setting-up and preparation of lifting

cranes and special implements is to be carried out in accordance with the construction

organization plans.

4.3 Voltage-withstanding test for electric porcelain products of should be made

according to JB/T5909.1-4.

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4.4 The manufacturer should tell the detailed technology to the erection contractor

and when necessary, send personnel for technical guidance during the erection..

5 Erection of the ESP Proper

See Appendix A for unspecified ESP erection tolerance.

5.1 Acceptance of the concrete foundations/pillars

5.1.1 Types of connection of steel column or support bearing with foundation should

be shown in Fig.1 & Fig.2.

Figure 1 Connecting type 1 Figure 2 Connecting type 2

5.1.2 The embedded parts and bolts must meet the requirements on the drawing .And

the strength of concrete must meet the design requirements. For allowable deviation

of the foundation, refer to table l.

Table Allowable Deviation of Foundation

Item Length, m Deviation, mm

Distance between ≤10 <±3
columns >10 <±5
Diagonal line ≤20 <±6
>20 <±8
Elevation ≤±3

5.2 Steel support structure

5.2.1 Mark the centre lines and contour lines of each plane of the support structure

and use them as bases of measurements.

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5.2.2 Allowable deviation in elevation of each loading point in the support structure is

≤±3 mm, and its verticality, ≤±5 mm.

5.3 Bearings

5.3.1 The bearings should be placed in strict accordance with the requirements of the

drawing. Attention should be paid to the directions of displacement of unilateral and

bilateral bearings. Temporarily fix the bearings. The temporary fixtures must be strong,

and they are removed or the fixing bolts are returned to where the drawing requires

after the bottom beam is erected but before the equipment is put into operation.

5.3.2 Deviation in elevation of each bearing as measured from its upper surface is

≤±3 mm.

5.3.3 All the welding between the support bearings and related elements should be

done by welding rods T506 or T507.

5.4 Bottom beams, dust hoppers

5.4.1 Mark the longitudinal and transverse centre lines on all bottom beams, lift the

beams into place and support them temporarily. Take measure of

deformation-resistance when applying welds. After a bottom beam is erected the gap

between it and the support point should be <1 mm.

5.4.2 Deviation in diagonal lines of bottom beams is shown on Fig 3. Deviation in

elevation of each column’s support point is ≤±3 mm.

Figure 3 Diagonal deviation of bottom beam

5.4.3 The inner walls of each hopper must be jointed by seal welding.

5.4.4 Upper gas screen plates in the dust hoppers are mounted after the collecting

plates are erected and adjusted. The gap between the bottom surface of the rapping

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bar in the collecting row and the gas screening plate there should be in strict

accordance with the drawing so as to maintain a minimum space of 35 mm to ensure

the collecting plate’s free thermal expansion. The cut-out in the upper screening plate

in the hopper can be modified on site.

5.5 Internal walkways

5.5.1 When the internal walkways are put into place, pay attention not to weld their

expandable ends. For the parts that are to guide the collecting plates, they should be

welded after the collecting plates are erected and adjusted.

5.6 Columns, inner roof and stairways

5.6.1 Before erection, measure the actual length of each column and prepare filler

pieces of suitable thickness. Then mark the centre lines and contour lines of all

measuring planes.

5.6.2 Allowable deviation in verticality of columns is ±5 mm. Allowable deviation in

elevation of columns is ±3 mm and that in distance between columns is ±5 mm.

5.6.3 Part of the platforms and stair ways can be erected after the inner roof is

installed to facilitate further installation. The stairways must be solidly and reliably

mounted, and attention should be paid to their thermal expansion.

5.7 Discharge suspension and major frame

5.7.1 Voltage-withstand tests should be made on the porcelain insulators before their

installation. When mounting the insulators, special care should be taken to avoid them

being broken. Allowable difference in elevation of insulators in the same group is ±1

mm. And allowable deviation between the centers of tie rod, dust screen tube and

insulator should be kept within ±3 mm.

5.7.2 Discharge major frames are to be assembled either partly on the ground or in

the electric fields. Refer to Figure 4. The upper middle and bottom minor frames are

usually assembled within the electric fields. After the minor frames are assembled, the

following requirements should be met:

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 a. The allowable deviation of the centers of the two rectangular tubes in the same

minor frame should be ≤±3 mm.

b. Allowable deviation in verticality of vertical beams is 3 mm.

5.8 Collecting system

a. Mark and elect the suspension frame of collecting plates.

b. Allowable deviation in distance between the suspension frame and the upper

minor frame is ±5 mm.

c. After the discharge system’s frames are installed in the form of a cage, lift the

collecting plates in to it. Each plate should be corrected and the tolerances in

dimension, shape and location should follow JB/T5906.

Figure 5 is the check stand for collecting plates.

Use a handling device (See Figure 6) to put the collecting plates one by one

into the guiding frame (See Figure 7).

Each plate is attached with a clamp after it is put into the frame.

Usually 5~6 plates are lifted for installation together.

d. Lifting can be done by means of either Figure 8 or Figure 9. Figure 10 shows

how the heads of the plates are attached for lifting. Figure 11 shows the

design of a lifting hook.

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e. During the process of plates’ insertion into the gap between the suspension

frame and minor frames, the guiding frame should be released layer by layer.

Correct the plates after they are located. Allowable deviation in voltage

distance is ±10 mm.

Huck bolts or high-strength bolts must be tightened by special tools.

Figure 5 Figure 6

Notes: Figure 5- Side checking frame of single collecting plate;

Figure 6- Tools for transport and lift of single collecting plate.

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 f. If the bottom portion of the collecting plates is fixed by using concave and

convex bushes, the tightening torque for the bolt should be 160 N.m.

5.9 Installation of discharge wires

5.9.1 Installation of tubular barbed wires. Check the wires and install them in strict

accordance with the approved drawings. No wire is allowed to be installed reversely

or upside down. The tightening torques at the round and oblong holes should follow

the requirements in the drawing, i.e. to enable the wires’ free thermal expansion but

not allow them to sway. Then weld the bolts dead. Allowable deviation in distance

between collecting plate and discharge wires in shown in Table 2:

Table 2 Deviation in Voltage Distance

Length of Plate Deviation

≤7m ≤5 mm

＞7m ≤10 mm

5.9.2 Erection instructions of spiral wires

a. During the erection of spiral wires these found to have surface scratches,

obvious material defects or loose contact with the hooks must be discarded.

During the period of erection, anti-corrosion measures should be taken to

protect the wires.

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 b. The spiral wires are to be stretched by a special tool with a cord (Fig. 12).

During the stretching of the wire, the wire must be allowed to turn freely. When

the wire is stretched to a point which is only 200~300 mm from the lower ring,

the erector should slow down his speed of stretching and gently insert the wire’s

lower hook into the ring. Overstretching the wire is forbidder. Any wire that is

overstretched must be discarded. Erection of spiral wires is requested to start

from both sides of the frame to the middle.

Figure 12 Special tool for emitting wire

5.10 Erection of the rapping system.

5.10.1 Erection must be in strict accordance with the approved drawings. Hammers

can be mounted on to a rapping shaft only after the shaft’s coaxiality is kept less

than 3 mm. The allowable deviation between the centers of the rapping hammer

and the respective anvil is ±3 mm horizontally and ±3 mm vertically.

5.10.2 All welds applied to the shaft and the anvil should be made with electrodes T

506 or T507.

5.10.3 Check the direction of rotation of the shaft. Manually turn the shaft to see if it is

all right. After energizing the motor, make a trial run of the rapping shaft: it should

rotate in the right direction.

5.11 Erection of the inlet and outlet nozzles and gas distribution plates

5.11.1 Depending upon the lifting capacity of the crane, the nozzle can be lifted after it

is entirely assembled.

5.11.2 Put the gas distribution plates in place exactly as per the drawings.

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5.12 Erection of the outer roof and the penthouse. Pay attention to the outer roof’s

thermal expansion.

5.13 Erection of ash discharge equipment, inspection doors and other mechanical

parts. After the doors are installed, check to see if they can be opened smoothly and

closed hermetically.

5.14 Thermal insulation and coating

5.14.1 The thermal insulation is designed based on the manufacturer’s practice and

the user’s requirements.

5.14.2 Coating of ESP should meet Q/FHK08

5.15 Lagging sheets should be securely mounted and give a good appearance.

6 Cautions during erection

6.1 While making erection plans, preventive measures for deformation due to welding

should be taken into consideration.

6.2 Missing welds and false welds are strictly forbidden, especially for internal parts.

6.3 Make sure the ESP casing is welded gas-light. Pay attention to the repair welding

at places where there are missing welds.

6.4 The adjustment of the spacing between the collecting plates and the discharge

wires is extremely important to the ESP performance such as collecting efficiency. The

collecting rows and discharge frames must be carefully inspected and adjusted to

within the allowable deviation in distance during their erection.

6.5 Take special care of the welding at the following places due to limited space

or too many stiffeners. Welds should pass 3-level inspection to avoid missing

or false welding.

a. Welds between the 4 corners of a hopper and the bottom beam bearing;

b. Welds between the stiffeners around the upper opening of a hopper and

the bottom beam;

c. Welds between the casing pillars and the longitudinal beams and

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 between the girder and the longitudinal and the horizontal beams;

d. Welds between the hoppers and the connecting plates of inlet and

outlet nozzles’ reinforcing rings.

7 Final Inspection of Erection

7.1 Dismantle and remove all temporary devices and scaffoldings. Apply remedial

welds where necessary.

7.2 Make an overall cleaning inside the ESP. No tools, metal scraps or other odds and

ends are allowed to be left inside. Seal the access doors tightly.

7.3 Porcelain insulators must be clean and neat.

7.4 Check the oil level of the speed-reducer to see that it meets the specified

requirement.

7.5 ESP casing and auxiliaries are firmly and properly earthed. Earthing bolts/nuts

and locking bolts/nuts are well connected and earthed in accordance with regulation

for electrical construction.

7.6 Remove the temporary fixtures for the support bearings or return the fixing bolts to

the required position.

7.7 Check the dielectric resistance of the discharge system to see that it meets

JB/T5909.1-4.

8 Items of commissioning after erection

8.1 The acceptance tests of ESP should be made as per JB/T5910.

8.2 The no-load voltage step-up tests of ESP should be made as per Appendix B,

“ESP’s Commissioning Program”.

8.3 Make gas-tightness tests of ESP casing by means of smoke bombs, kerosene

penetration etc.

9 Mounting of High-strength Bolts

They should be mounted as per relevant standards.

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 Appendix A
(Normative Appendix)

Undeclared erection tolerance list of ESP

Table A 1 Erection Tolerance on Length

Length (m) Tolerance (mm)
≤4 ±3
4-7 ±6
7-10 ±8
10-15 ±11
15-20 ±14
20-25 ±16
25-30 ±18
>30 ±20

Table A.2 Erection tolerance for diagonal measuring

Note: The above table A.1，A.2 include manufacturing tolerance.

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 Appendix B

(Normative Appendix)

Commissioning Outline of ESP

B1 Contents of commissioning

In order to make the ESP wants to reach the expected effect, it must have good

erection quality, and the commissioning work after the erection is the essential way for

inspection and erection quality guarantee. The commissioning is often includes:

a. Inspection and testing of ESP components;

b. Air tightness test of ESP;

c. ESP inspection and adjustment after the erection;

d. Inspection and commissioning of the LV control loop of ESP;

e. Inspection and commissioning of the HV control loop of ESP;

f. Commissioning for ESP collecting and emitting rapping, distribution plate

rapping and the driving parts of ash-discharge mechanism;

g. Commissioning of energized ESP electric heating;

h. Load commissioning of cold & smokeless fields of ESP;

i. Hot state load commissioning of ESP.

B2 Preparation work and safety considerations before the commissioning:

B2.1 The commissioning work of ESP should be executed by the erection contractor.

The relevant people such as the representatives from the construction contractor,

manufacturer and user etc. should join in. Appoint a commander in chief leaders for

each field of commissioning, clarify the commissioning operational mechanism

(organization, director, work quantity and personnel), and prepare an engineering

sheet. If there is any problem, it should be coordinated and settled in time. During the

commissioning, arisen problems, solutions and all kinds of data should be recorded

seriously. After finishing the commissioning, write down the conclusions in the

commissioning report, and submit to relevant sections and units.

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B2.2 The commissioning staff should read the equipment specifications and relevant

technical data seriously and be familiar with the equipment and systems. They should

work according to the items, methods, steps and requests specified in the

commissioning program.

B2.3 Prepare the consumable materials, greases and apparatuses and tools which

are needed in the commissioning work. Main apparatuses and tools are as follows:

a. Electrostatic voltmeter 100KV 1 piece (digital electrostatic voltmeter is

preferred);

b. Digital multi-meter 1 piece;

c. Tong-type ammeter 1~5A 1 piece;

d. Megohmmeter 2500V, 500V 1 piece for each;

e. Voltmeter 600V, grade 0.5, 1 piece;

f. Typical electrician commissioning tool 1 set;

g. Incandescent bulbs with rated load of 220V, 100W*2, 1 set (of self make)

h. Insulating rod 10KV triarticular, 1 set (for the use of electric discharge);

i. Sign boards and ropes a lot (user-provided);

j. Testing connection plastic-coated multiple-cored wire a lot (user-provided );

k. Energetic interphone 1 pair (for a use in high-rise arrangement).

B2.4 Composition of personnel for commissioning:

Commander in chief: 1

Operator: 2

Inspector and gauging person: 2~3

Adjuster: Mechanical 2~3

Electrical 2~3

Coordinator 1~2

Total: 10~15

B2.5 Some confirmations

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 a. Communal facilities are all ready (water, compressed air, electricity and so on);

b. Confirmation of relevant equipment such as power supply device, oil supply

and drainage equipment, fire-fighting equipment and so on;

c. Confirmation of the insulation resistance of main loop;

d. Confirmation of the programmed check of control loop.

B2.6 Records of checking and testing results will be effective only with the cosigner by

the manufacturer, the erection company and the user. After the commissioning, a

final report will be prepared with the three parties’ signatures and then will be

filed.

B2.7 Safety considerations should follow the rules of JB6407 standard.

B3 Inspection and testing of ESP components

B3.1 Check the main insulating parts of H.V. net, such as H.V. isolating switch,

emitting suspension insulator, emitting shaft insulator, feed-through insulator, etc.

They all should pass voltage resistance test. Use a 2500V megohmmeter to

measure the H.V. net. Before the insulation piece is contaminated, its insulation

resistance value should be more than 1000 MΩ.

B3.2 Before the assembling and commissioning of H.V. silicon rectifying transformer,

check to see that the air in the buchholz relay should be discharged.

B3.3 Check to see that the H.V. isolating switches can be operated agilely and can

reach the right position. For switches that have secondary contacts, the contact

points’ combination and dividing will be agile.

B3.4 Check the cable head, to see there should be no oil leak phenomenon.

B3.5 Items which should be tested before the commissioning of H.V. silicon rectifying

transformer should follow the operating instruction manual for electric control

equipment.

B3.6 If the H.V. output of the silicon rectifying transformer is using H.V. power cable,

the H.V. cable should be tested as follows:

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 a. H.V. cable oil strength test: its one-off breakdown voltage should not be less

than 35KV standard oil cup;

b. H.V. cable direct current leakage test;

Use a 2500V megohmmeter to measure the cable insulating resistance value

before the test and also is after the test;

The voltage of direct current withstanding voltage test for the special direct current

cable of ESP is 2 Ue (the double rated voltage),for 10 minutes;

If other specification power cable is used for substitution, its withstanding voltage

standard and the duration should follow power cable direct current withstanding

voltage test standard of GB “Erection Work Construction and Acceptance

Specification of Power Installation (GBJ232-82) (Chapter 17: Electrical Acceptance

Test Standard)”

During the tests: Voltage can be stepped up by increments of 0.25, 0.5, 0.75, 1

time the test voltage. Each step will stay one minute. Leakage current value will be

read. When measuring, the influence of stray current should be removed.

B3.7 If one of the following problems appears in the cable direct leakage current test,

it means cable insulation may have defects. The defective part should be found and it

should be dealt with:

a. Leakage current is very unstable;

b. Leakage current is sharply rising with the rising of test voltage.

B3.8 The test of control cabinet should be done according to the operation manual of

electric control equipment.

B3.9 All sorts of insulators installed on ESP, including feed-through insulator, emitting

support insulator, rapping shaft insulator and so on, should be inspected for their

exterior surface before the installation according to the electric insulator standard. The

insulators should be perfect with no damage and cracking.

B3.10 All sorts of insulators should undergo the insulation resistance measurement

18
and AC withstanding voltage test before the installation and this should accord with

manufacturer’s regulation. (General regulation: under ordinary temperature: they can

withstand 100KV voltage for one minute)

B3.11 Motors on rapping, dampers and ash discharge gear should be inspected

before the installation. Bearings should be greased according to the regulation.

B3.12 The type and parameters on the nameplate of electric heater should accord

with the design requirements. Before the installation, visual inspection should be done

with no damage found. Using a 500V megameter to measure the insulation resistance,

and the value should be more than 50MΩ. If it is less than 50MΩ,the heater should be

dried by applying low voltage electricity.

B4 ESP sealing test: After finishing the ESP installation, and before laying the

insulation, sealing inspection should be done. For sealing inspection, either kerosene

penetration test or smoke bomb test can be used.

If smoke bomb test is used, the way is as follows:

B4.1 Purpose: Using smoke from the 65-1 military fuming can to check the sealing

condition of the ESP proper.

B4.2 Preparation work:

a. Properly sealing the ESP proper, including: I/O ducts, hoppers, and

inspection doors etc. should be sealed and closed with suitable means;

b. Each time prepare three 65-1 military fuming cans for every ESP, one of the 3

cans is spare;

c. One axial flow blower should be installed at the inlet of specified inspection

door;

d. 2~3 gas masks should be prepared;

e. Enough fire-fighting materials should be prepared and all should be put at the

assigned place;

f. Prepare one keg of white paint, and several writing brushes;

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 g. Organize 6~10 inspectors, each one takes charge of a section.

B4.3 Air-tight test:

a. Fuming cans should be put on the internal walkway;

b. Lighting up the fuming cans (for method of application, refer to the operation

instructions of fuming can). After the fuming can is fuming normally, people

should come out and the door should be closed at once;

c. Start the axial flow blower to pressurize the inner of casing;

d. According to the division of work, check if there is any smoke leakage and

use white paint to mark the exact place where there is a leakage;

e. Open the inspection doors and remove the inner smoke. Stop the axial flow

blower, and do the repair welding according to the marks;

f. Repeat the smoke bomb test until there is no leakage in the whole sealing.

B4.4 Safety measures:

a. During the working time, all firing people must wear gas masks;

b. After the fuming, all staff must leave the inner of the ESP. After closing the

inspection door, blower fan would be started;

c. Fire fighting equipment must be prepared on site;

d. When the cans are fuming, no repair welding for leaking area is allowed.

B5 ESP inspection and adjustment after the erection:

B5.1 The inspection and adjustment of the center-to-center distance between emitting

and collecting electrodes:

a. Collecting plates should be 100% corrected on the ground, they are 100%

rechecked and recalibrated;

b. The quality of emitting wires should be checked one by one. If there is any

defect or it is extended beyond its working length during the installation, the

emitting wire should be rejected and replaced;

c. Check all walkways, and the front and back of each walkway should be

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 checked;

d. In the walkway, the deviation of different electrodes should be accorded with

the requirements of JB/T5910 standard: when the height of collecting plate

h≤7 m, the limited deviation between different electrodes will be ±5 mm, if h＞

7m, the limited deviation will be ±10 mm;

e. During the inspection and adjustment, in the vertical and horizontal direction,

all walkways should take the distance from the out wall of every vertical

square pipe for the emitting minor frame to the flange outboard of wind

proofing channel of the collecting plate as a check point;

f. In the vertical direction, check 5~9 points for one side of each walkway, i.e.

one point of each horizontal supporting pipe on emitting minor frame will use

tailored “T” gauge for testing, and records should be made. Unqualified parts

should be readjusted and reworked;

g. During the adjustment, it should be done slowly and carefully. Do not

overexert to the collecting plate;

h. Use heating method for correction is forbidden.

B5.2 All sharp angles and burrs in every part of the collecting and emitting electrodes

should be removed. The inner of casing field except emitting wire and collecting plate

should be checked carefully. In the field, the places where the distance between

emitting system and other insulators is less than the distance between different

electrodes should be dealt with.

B5.3 Bolts for every part of collecting plate, emitting major frame, emitting minor frame,

collecting & emitting rapping should all be tightened and welded dead.

B5.4 The contact position of emitting & collecting hammer and anvil should accord

with the requirements. Shafts and hammers should be rotating agilely.

B5.5 Foreign matters in the field should be cleaned up.

B5.6 Check if the damper motor, rapping speed reducer motor, ash discharge motor

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etc. are rotating smoothly or not. The tightness of chain is moderate. Each lubricated

part should be cleaned and oiled.

B5.7 The sealing tightness of adjusting gate, baffle, induced draft fan, ash discharge

device, roof panel, inspection door which are connected to the duct are very well.

B5.8 The welding seams for each part should be deep-set. There is no wrong welding

or missing welding, and the sealing tightness is very good.

B5.9 Each support insulator should contact stably and should be under uniform stress.

Each shaft insulator and feed-through insulator should be clean and dry.

B5.10 The ESP proper’ s earthing resistance should be less than 2Ω.

B5.11 Use a 2500V megohmmeter to measure the insulation resistance of the voltage

regulating net, and the value should be more than 1000 megohm.

B5.12 The ESP shell and the positive electrode cable of H.V. T/R should be perfect

and tightened.

B5.13 The operating mechanism of H.V. isolating switch should be flexible and in the

exact position.

B5.14 Use a 500V megohmmeter to check the rapping motor, damper motor, ash

discharge motor and the insulation condition of cables. Their insulation resistance

should not be less than 0.5 megohm.

B5.15 Check the wiring between each part is right or not as per the drawings.

B6 Inspection and commissioning of low voltage control loop of the ESP。

B6.1 After the wiring inspection of the ESP electrical system is finished, energize the

ESP and then make the driving test of each system and no load commissioning test

for the equipment.

B6.2 Low voltage operation control unit should be powered on for check. Main items

include: Alarm system test, rapping loop inspection, ash discharge loop inspection,

heating and temperature test loop inspection and so on.

B6.3 Before the ESP is powered on, wires which connect each cabinet and ESP lower

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voltage components should be disconnected from the terminal block. After it is

powered on, each power switch on the cabinet should be started and each supply

voltage meter on cabinet should have indications.

B6.4 During the alarm system is manually started or automatically started, its

instantaneous, delayed sound and light signal should act exactly and relieve reliably.

B6.5 Methods and requirements for rapping loop inspection are as follows:

a. Trial operation: first the contactor in the panel should be disconnected from the

power line of the motor, then the switch should be closed and current should be

delivered.

Manual mode: switch on and switch off for 3 times. The contactor’s switch on and

switch off should be correct. Signal light word board should be as per design

requirements.

Automatic program control mode: set a rapping cycle, repeat action for 3 cycles.

Rapping time sequence should be correct. Switch on and switch off of main loop and

signal light word should be correct. Testing rapping time on site can be adjusted.

After tests are finished, power should be cut off and the motor connection should be

recovered;

b. No load operation: shaft coupling should be disconnected, and the switch

should be closed and current should be delivered:

Manual mode: After startup. Check the rotating direction of the motor, it should

be in accordance with the requirement of the control unit. Switch on and switch off for

3 times. Starting current value, no load current value and each phase current value

should be measured.

Automatic program control mode should be executed to work for 3 cycles. All

executions should be correct.

After the test is correct, power should be cut off and the coupling of shaft

coupling should be recovered;

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 c. Cold-run commissioning operation under the rated load; the switch should be

closed and current should be delivered.

Manual mode: starting current value should be recorded during the

commissioning. Current value of three phases should be measured. Checking the

setting value of protected unit is exact or not. Switch on and switch off 3 times and all

should be normal.

Check the contact point where the hammer is rapping at the anvil. Its all pre

reserved values should be as per design requirements. Rotating is agile and there is

no phenomenon as hammer lock, hammer drop and blank hammer.

Automatic program control mode: Try to rap for 3 cycles and the execution

should be correct.

After the mechanical and electrical inspections are qualified, it should be normal

when the continuous rapping is going on for not less than 8 hours.

B6.6 The method and requirement for the inspection of ash discharge loop and ash

conveying loop are as follows:

a. During the trial operation: Power supply wiring of the motor should be taken

apart for the lower end of the terminal block, then the switch should be closed and

current should be delivered.

Automatic mode: manually simulate the operating condition of ash level should

be tandem driven for 3 times, and the interlock should be correct.

After the test is passed, power should be cut off and the motor connection should

be recovered;

b. No load trial run: Untie the mechanical load of ash discharging-mechanism.

Power on and make the motor trial run.

Manual mode: Start the motor, and make sure its rotating direction is correct. The

starting current value and three phase current value of the motor should be measured.

Installation unit should follow the signal indication.

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 Automatic mode: Simulative start and stop for 3 times. The position signal and

interlock should be correct.

After no load trial run is normal, power should be cut off and mechanical load

should be recovered.

c. Trial operation with ash discharge mechanism

Manual mode: When it is started, starting current value and three phase current

value should be measured and current setting value of thermal element should be

checked.

Automatic mode: Simulative starting for 3 times, trial operation should be normal.

For the thermal state ash level linkage test, it should be done under the actual

operating conditions later.

After mechanical and electrical inspection is qualified, continuous trial run should

be in process for 8 hours. It is required that the rotation should be agilely and there is

no phenomenon of locking or sticking.

B6.7 Inspections of the undercurrent heating alarm and the temperature test loop. Its

method and requirement are as follows:

a. Manual operation: After it is powered on for 30 minutes, measure the current

value, and check the current setting value of thermal element. Signal and

installation unit should be correct;

b. If the heating loop is equipped with undercurrent alarm, any of the electric

heaters in this loop should be removed manually. Undercurrent alarm should

be activated;

c. Temperature control mode: Simulative start and stop for twice. Contactor and

signal should be correctly activated. Temperature control range should follow

the design requirements. After it is powered on for heating, if the temperature

rises to upper limit setting value, heating should be automatically stopped. If

the temperature drops down to the lower limit setting value, the heating

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 device should start automatically.

B6.8 Low voltage control loop commissioning should be executed according to the

commissioning specification from the power supply manufactory.

B7 Inspection & commissioning of ESP H.V. control loop

B7.1 Operation test of H.V. silicon T/R control loop

Under the condition of disconnecting the L.V. side wire of the silicon T/R, make

local and remote switching test, test items including simulating gas, over current, trip

drive with temperature limitation protection, liquid level, temperature warning & safety

linking, air cooling interlocking, etc. All the lighting, sound and signal should be

correct.

B7.2 Commissioning of H.V. control loop includes: setting of the controlling inserts and

adjustment of limiting parameters for no load test equipment in an open loop and a

closed loop.

B7.3 Inspection before commissioning of H.V. silicon T/R control loop

a. Inspect to see the internal and external wiring is correct according to

equipment skeleton drawing;

b. The inspection of unit component and discrete component should comply

with relative requirements.

B7.4 Commissioning of H.V. silicon T/R control loop should be carried out as per the

procedures and requirements in the commissioning program, which is generally

divided into 2 steps, open loop and closed loop.

B7.5 Open loop test method and requirements of H.V. silicon T/R control loop as

below:

a. The open loop test can be done at a simulating table or controlling cubicle,

the measuring of each static parameter can be adjusted with controlling

inserts. If tested on a controlling cubicle, disconnect all wires in the main loop,

and connect two lamps (220V, 100W for each one) to be nominal loading;

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 b. For detailed test method see the operation manual of electric controlling

equipment

B7.6 Closed loop test should be executed according to the commissioning manual of

electric controlling equipment.

B8 Commissioning of the ESP’s discharging rapping, collecting rapping, screen plate

rapping and driving mechanism:

B8.1 Intention

In order to guarantee the safe operation of the ESP, the discharging rapping,

collecting rapping, gas distribution screen rapping and ash-discharge devices must

undergo trial-run separately during the installation and before ESP is put into

operation, to check the running condition of driving and rapping parts, and to make

sure that they are in good condition.

B8.2 Preparations:

a. Before installing the driving equipment, make an overall check completely to

the rapping frame, rapping driving shaft and rapping hammer which have

already been installed;

b. Remove burr and welding spatter on all parts;

c. Erected dimensions should comply with the requirements of applicable

drawings;

d. Manual rapping hammer should be able to rotate freely;

e. For collecting rapping, the hammer should strike on the centre of the anvil ±4

mm, and the angle of the adjacent rapping hammer should comply with the

requirements of applicable drawing.

Check the oil level and oil plug of reduction box.

Check the air tightness of rapping shaft.

All bolts & nuts should be tightened and welded dead.

f. For the discharging rapping, the matching of pin wheels should be correct.

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 Clear the shaft insulator and remove rubbish.

Check the air tightness of driving mechanism, the angle of two adjacent

hammers should accord with the requirements of applicable drawing;

g. Gas distribution rapping can be in process according to the articles of

collecting rapping.

B8.3 Trial-Run

B8.3.1 Collecting Rapping:

a. Carry out 2-hour no load running test for the collecting motor, to check

whether there are abnormal heating phenomena, vibration and noise, and

remove such abnormity;

b. Execute trial-run, to check whether there is locking phenomena and remove

it;

c. Rotation as per the rapping direction during trial run, not to rotate in the

reverse direction, which should be checked by personnel at site;

d. Start up the collecting shaft system, stop it by pressing the emergency button

when the motor reaches its maximum speed, if the shaft system has rotated

less than one cycle, start it up again as per the above method. Do not switch

on the power supply to run continuously until there is no problem;

e. Make trial run for 1 hour according to the requirements. Inspect completely

after it stops, the erection is qualified if there is no abnormity.

B8.3.2 Discharging Rapping

Commissioning should comply with the article B8.3.1.

B8.3.3 Gas Distribution Screen Rapping

Execute as per article B8.3.1.

B8.3.4 Ash-discharge Equipment

Execute as per article B8.3.1.

B8. 4 Finishing Work

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 a. Switch off power to all the motors, seal the local switches;

b. Keep air tightness of the wall holes for rapping shafts;

c. Remove all remaining foreign things.

B8.5 Safety Measures:

a. All the motors should be operated by electric personnel;

b. It is not allowed to make adjustment and repair when the ESP is running;

c. It is necessary for the internal of ESP to have enough lighting during

inspection.

d. Prepare enough fire-fighting tools.

B9 Commissioning of ESP electrical heater

B9.1 Before the installation of electrical heaters, the types and parameters marked on

the nameplate should be checked to see whether they are according to the design

requirements or not, and the insulation resistance, which should not to be less than 50

MΩ, should be measured. Test value of AC voltage resistance should be AC 2000V at

line frequency without flashover or break through for one minute.

B9.2 Before the application of voltage rating, measure the insulation resistance first to

confirm whether it is as per the requirements, if there is a long time before ESP’s

running since the installation is finished.

B9.3 Turn on the electric heater to check

a. Whether there is open circuit or not;

b. How fast the temperature is rising;

c. Whether the range of temperature controlling is correct or not.

B9.4 The test of Thermostat-controlled electrical heaters can be executed only after

normal gas is passing through the ESP.

B10 ESP’s cold load commissioning is without gas.

B10.1 After the HV thyristor rectifier passes the no-load performance test, the ESP

can undergo cold load test without gas passing through.

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B10.2 Sequence of cold load commissioning without gas:

Put the LV operating & control devices, especially the heating loop, into operation

first. Check the devices to see that they work properly. Then put the HV system into

operation and carry out commissioning.

B10.3 Before the HV system is put into operation, make sure that the LV system

meets the following:

a, The rapping systems are working properly , the rappers for each field operate

in the design order , and the rapping time and cycle should meet the set values ;

b. The ash conveying and unloading systems are working properly, and the

unloading time and delay time should meet the set values;

c, Each temperature-measuring and indicating unit is adjusted as per systems ,

and the measured and shown values are correct .

B10.4 Procedure of voltage step-up test: First carry out the static voltage step-up test;

then carry out the dynamic voltage step-up test.

Notes:

(1) By static voltage step-up test, it means that the ESP’s rapping systems are off

and the I.D. fans at the ESP’s outlet are off, too. That is, the fields are in a static state.

(2) By dynamic voltage step-up test, it means that all the LV and HV systems of

the ESP are operating except that there is no gas passing through.

a. Before the voltage step-up test in individual fields is carried out, first put the

heating system for insulator chambers into use. Open the inspection doors of

chambers, remove all the humidity on the chamber walls and on the insulators, then

close the doors and turn on the HV isolating switches the components of which should

be exactly positioned. After the field is energized, turn on the oscillograph and pay

special attention to the ware form of the current feed-back signals. Press the start-up

button and both the current and voltage should rise slowly. Watch closely the meters

on the control panel and the current feed-back wave form. When there is a failure in

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the protective link, the HV electric equipment will be damaged. During the normal

voltage increase, all the meters on the control panel should have corresponding

indications and the current feed-back wave form should be symmetrical dual

half-wave.

b. During the initial period of voltage step-up, if the primary and the secondary

currents rise rapidly but there is no indication on the voltmeter, there is a short circuit

in the secondary loop. When there are primary and secondary voltages only and they

rise rapidly, the secondary loop is open. When there are indications for the secondary

voltage and current while the primary current is greater than the rated value, the

primary voltage is around 220V and the angle of ignition is greater than 95%, there is

breakdown in an individual thyristor igniter or in one group of the HV silicon stack.

Should the above-mentioned abnormal phenomena occur, the voltage must be

brought down and the ESP turned off immediately. After trouble-shooting is carried out,

the ESP can be re-energized to step up the voltage.

c, During the voltage step-up test , when the secondary voltage is far below its

rated value , there is flashover in the HV net or in the related field . If there is no

flashover in the HV net or the field, but the flashover-controlling link in the HV control

system is working, “false flashover” will occur. In such a case, corresponding

adjustment should be made on the taps of the HV thyristor T/R set, on the taps of the

reactor and in the control section until the “false flashover” disappears.

d. During the voltage step-up test, all the meters should be calibrated. HV static

meters can be used to measure the outlet of the HV T/R. For the convenience of

calibration, the indication on the secondary voltmeter can be calibrated when the

secondary voltage is raised to 40~50 KV and when there is no flashover. At the same

time, use a megameter to measure the feed-back sampling resistance and take it as a

fixed value. Then, according to Ohm’s law the indication on the secondary ammeter

can be calibrated.

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 e. The adjustment of the taps of the HV T/R and reactor can be made on the

basis of the current feed-back wave form. The principle is: Adjust the tap until the

wave form of the current feed-back signal becomes round and smooth with a

maximum angle of ignition. To make the wave form as close as the ideal form is

mostly desired.

B10.5 Test of no-load voltage step-up with parallel energization:

Since the capacity of a HV T/R is determined by the current densities on both plate

and wire as well as the breakdown voltage under the condition that there is gas

passing the ESP , when the voltage step-up test is made in an ESP with air only , due

to the greater current density of the air , the capacity of a HV T/R energizing a single

field would usually not be fixed . That is, the secondary current would be locked after it

reaches the rated value, while the secondary voltage can’t reach the breakdown value.

In such a case, two HV T/R sets of the same capacity can be linked in parallel to

energize a single field. Main points follow:

a. The so-called parallel energization as mentioned above must be carried out

after each of the two HV T/R sets is separately adjusted for the same field and it has

been confirmed that there is no trouble either in the power source or in the field to be

tested . To energize in parallel, connect the two T/R sets after the damping resistors.

This can be realized either by HV isolating switch to switch over onto a linking bus bar

or by a conductor whose discharge distance is guaranteed ( over 300 mm form the

ground) . During the energization by two T/R sets, start-up should be synchronous by

means of the selection switches of “Manual step-up” and “Terminate” to step up the

voltage of the two T/R sets at the same time. If the same of the current value of the

two T/R sets is not up to the rated value, keep the rise of the voltage until there is

flashover in the field . At this point, the secondary current is the sum of the two T/R

set’s current values and the secondary voltage is the average of their secondary

voltage values.

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 b, During the no-load voltage step-up commissioning , special personnel should

be assigned to supervise if the HV T/R sets are functioning properly . When the T/R

sets are located on the ESP’s top, there must be longer primary power cables, so the

input voltage on the T/R set’s primary side must be measured and compared with the

indication of the primary voltmeter on the control panel. If the difference is big, make

trouble-shooting.

c. During the HV tests of the fields , make records of all date , such as the

secondary voltage ( after the corona-initial voltage ) corresponding to a small

secondary current ; the primary voltage and the primary current each time when the

secondary voltage is increased fields should be drown. The V-I curres for all the fields

should be similar to each other. If there is difference, further treatment should be

made until the curve is up to requirements. For fields using barbed wires with a

voltage distance of 150 mm/200 mm, their secondary voltage can be as high as 20

KV/65 KV or more. For fields using non-barbed wires with a voltage distance of 150

mm /200 mm , their secondary voltage can be as high as 55 KV/70 KV or more . For

spiral wires, only tests for V-I curres are made and no test for breakdown voltage is

allowed.

B10.6 Dynamic no-load voltage step-up test: If conditions are available, the ESP can

be in continuous operation for 24 hours. Then make an overall inspection on all the

working loops to check their status. Solve all troubles thus found.

B11 ESP’s hot commissioning with load (72-hour continuous operation)

B11.1 After the ESP has passed the above static and dynamic no-load voltage step-up

tests, its electric equipment has reached such a condition as to allow flue gas to feed

in. At this point, its mechanical portion should still meet the following:

a, Both inlet and outlet ducts of the ESP have been installed . The boiler is ready

for operation. The I .D. fan has passed the trial run.

b. The whole ash-unloading and conveying system has been installed. The water

33
pumps for ash flushing have passed trial run. The water volume for ash flushing has

been adjusted to a suitable level.

B11.2 Flue gas enters the ESP. All inspection doors are tightly closed. LV power suppy

and heating system is on to let temperatures in insulator chambers higher than flue

gas dew point, hence no electric creepage on insulators’ wet surface. By using flue

gas to warm up the ESP , the insulation resistance in the fields is increased to over

500 MΩ , when measured by a 2500V megameter .

B11.3 When the boiler is fired by oil at the initial stage, no HV can be put into use. This

is to avoid any explosion caused by oil within the ESP. This is also to prevent the

plates and wires form forming oil film, which will lead to corrosion. HV can put into use

only the ESP has a load of over 60% and only coal powder is fired (oil guns are

withdrawn in principle).

For boilers using coal gas for ignition, safety operation regulations should be

strictly followed. No HV can put into use before the boiler runs properly in order to

avoid explosion.

Step up voltage in all fields. Compared with the no-load tests, this time both the

field breakdown voltage and the secondary current are lower.

B11.4 Select the optimum operation mode as per the field conditions and make the

following settings:

a. The under voltage value should be set to be lower than the lowest corona-initial

voltage;

b. The measurement of the spark flashover threshold voltage should base on the

flashover status in the fields. Adjust the threshold voltage to enable it input the

blockage signal;

c. Draw the V-I curres of operating fields with hot gas and record the values and

wave forms at the main measuring points.

B11.5 Suitably adjust the spark ratio as per the operation conditions of each fields.

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Normally the spark ratio in the inlet field is 20~40 sparks/minute, in the middle fields,

10~30 sparks/minute and in the outlet field, 5~10 sparks/minute (or stabilized at a

higher corona power). For dust with high resistivity, the spark ratio can be increased to

a suitable extent. The actual spark ratio obtained after the efficiency test should

govern.

B11.6 If there is high dust concentration, great gas velocity and uneven gas flow

distribution in a field, there will be frequent flashovers, which can eventually turn to

arcs. In such cases, the sensitivity of the arc-quenching link can be adjusted to

restrain the produce of arcs. However, if the flashover is proper, the arc-quenching link

should not act.

B11.7 During the operation of ESP with flue gas, the operating modes of the fields are

different. It is necessary to adjust the taps on the T/R set’s primary side or on the

rector, bassed on the actual operating mode, to make the current and feed-back wave

forms smooth and full.

B11.8 Commissioning of LV control system

B11.8.1 For the rapping loop, mainly adjust the rapping time and the rapping cycle.

Their settings are basically based on the results of efficiency tests. Ideal settings can

also obtained by repeated adjustments after checking the status of dust adhering to

the plates and wires when the ESP has stopped running.

B11.8.2 Adjustment of the ash-unloading time:

For hoppers with upper ash-level indicator and control, the ash-unloading time must

be adjusted according to the actual ash volume from each field. Principle for this is to

keep the hopper filled with ash for 1/3 of its height. For the elongation of the

ash-conveying time, the principle is that all the ash within the conveying line can be

entirely transported. For hydraulic ash conveying system, the volume of the flushing

water should be adjusted to such an extent that all the ash deposited in the ash silo

can be flushed.

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